SAGD Operations - cdn.osisoft.com€¢ Assist in SAGD operations, & asset reliability & optimization...

© Copyr i gh t 2014 O SIs o f t , LLC .

Presented by

Using the PI

System to Improve

Safety at Suncor’s

SAGD Operations

Tripti Somani

Tom Luo


Agenda

• Suncor at a Glance

• History with the PI System

• Improving Safety and Performance

– Observations wells monitoring for Steam-Assisted Gravity Drainage (SAGD) operations

– Safety Interlock Bypass Monitoring and Reporting

• Concluding Remarks

2

© Copyr i gh t 2014 O SIs o f t , LLC . 3

About Suncor


Canada’s Leading Integrated Energy Company

• HQ in Calgary

• 14,000 employees

• Global E&P ~170 kboe/d

• Oil Sands – ~499 kbbls/d

• 4 Refineries – 460k kbbls/d

• +1,500 Petro-Canada stations

• 6 wind farms – 255 MW

• 1 Ethanol Plant

4


Our Journey from a “Historian” to an Infrastructure

5

• First PI System installed in 2006 at Firebag SAGD

• Current installed base– 4 sites/18 EA PI System servers, 2 non-EA sites/3 server w ~100k tags

– PI-AF, PI Notification, PI ACE, and other advanced functionality

– Remote asset surveillance and support of all PI installations (Managed PI)

• EA Signed in late 2009 covering our In Situ operations

• EA Expanded in late 2012 to include Oil Sands (Mines, Extraction, Upgraders, E&U)

• Key areas of Use:– Operations visibility and KPI

– Energy and environmental regulatory reporting (WPT, MARP)

– Plant & Asset performance and monitoring

– Assist in managing safety


Steam-Assisted Gravity Drainage (SAGD)

• Approximately 80% of Canada’s Oil Sands too deep to mine

• Two key SAGD facilities – Firebag & MacKay River

• Parallel pairs of horizontal wells are drilled: – one for steam injection

– one for oil recovery

• Safety and Operational challenges:

– Large numbers of assets and instrumentations

– Complex logic and criteria

– Process Changes

6


Solution Results and Benefits

Enhancing SAGD Operational Safety &

Reservoir Monitoring & Optimization

Business Challenge

• Identify abnormal pressure,

temperature and steam migration

outside of the reservoir

• Real-time information for large

number of wells and conditions

• Selected and installed the

PI System as a real-time

integration infrastructure

• PI System infrastructure

key components - PI-AF, PI

Notifications

7

• Enable enhanced safety,

environment & production

• Assist in SAGD operations, &

asset reliability & optimization

• Continuous improvement, and

collaboration

“Any abnormal reservoir responses are captured

automatically and alert the responsible parties

immediately, so that prompt actions are taken place

to ensure a safe operation.“

Manager Reservoir Management, Firebag


Proactive Reservoir Monitoring – The Role of Observation Wells

8


Legacy Monitoring System without PI AF

9

C#

Challenges:

- Longer development time

- Unhandled exceptions trigger false alarms

- Challenge to manage business change requests


Synchronization of Object Models

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System ModelProduction Model


PI AF and PI Notifications

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• Ease of use • Templates to set up new notifications

• Support & development

• Better Exceptions handling

• Highly reliable than custom code

• No False Alarms

• Historize notifications

High or lower levels alarms available on DCS.


PI AF and PI Notifications

12


Blanket gas pressure increased Investigation End of alarm status

Alert type: High Blanket Gas

Pressure

Reservoir Engineer called the field

to get the confirmation that there

was a hydrate/freezing in the

pipeline which caused the blanket

gas pressure to increase.

High Blanket Gas Pressure

Alarm Ended.

High Blanket Gas Pressure

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Blanket gas pressure

Tubing steam rate

Casing steam rate


Low Flow alerts on ESPs (electric submersible pump)

14

A Low Flow event was detected

in one of the pumps based on

wellhead temperature fall off

• Lost production

• Potentially fail of an ESP, around

$0.5 million at risk

• 130+ wells at Firebag

Wellhead temperature

Motor current


Solution Results and Benefits

Using the PI System to Monitor

Critical Interlock Bypasses and

Equipment Trips

Business Challenge

• Thousands of bypass tags

• Custom logic and reporting

requirements

• Multiple points can be used

to monitor one bypass

• Monitor, report, and audit

safety critical bypasses

through

• PI Data Access

Server,

• PI JDBC

• ETL and BI

It is very important to continuously monitor

and audit safety critical bypasses as

bypasses compromise the protection

functions that are designed to protect human

Health & Safety and the Environment.

15

• Improved governance of

critical interlock bypass

• Ability to track bypass

history for audit purposes

• Enable risk mitigation

planning (responsible

groups, bypass duration)


Example - Bypass in Control System


Corp Data

Oracle

SQL

DCS

17

DCS -> PI System ->

PI JDBC -> SQL ->

Business

Intelligence Tools

Data Flow for the Bypass & Equipment Trips Monitoring


Extract history from PI Archive into SQL

jdbc:pisql://localhost/Data

source=FIREBAGPI; Integrated

Security=SSPI; command timeout = 1200;

JDBC driver: com.osisoft.jdbc.Driver


Equipment Trip Report

To be replaced with Event Frames

to understand Downtime and

Overall Equipment Effectiveness


Closing Comments

1. Increased data availability to users through PI System

2. Assist in following operations strategy and optimize production

3. Enhanced decision making & collaboration

4. PI AF enabled us to meet rapid business growth

5. Increasing PI System installations with the EA

6. What is next?

– PI Event Frames and PI Analytics

– Migrate custom alerts to PI AF

7. Use of PI system to assist in improving safety

20


Brought to you by


Contact us

• Tripti Somani, Manager Applications and

Infrastructure

• [email protected]

• Tom Luo, Lead Historians and Database

• [email protected]

22

mailto:[email protected]

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